US10164374B1

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Publication number: US10164374B1
Application number: US15/799,744
Authority: US
Inventors: William G. Reed
Original assignee: Express Imaging Systems LLC
Current assignee: Express Imaging Systems LLC
Priority date: 2017-10-31
Filing date: 2017-10-31
Publication date: 2018-12-25
Anticipated expiration: 2037-10-31

Abstract

A twist-lock connector that includes a printed circuit board component with one or more flexible portions is disclosed. The flexible portions may be formed within an interior portion of the printed circuit board by routing or otherwise removing a portion of the printed circuit board to create one or a plurality of side for each flexible portion. One or more electrical contacts may be positioned on each flexible portion and arranged to be electrically coupled with male electrical contacts that are part of a corresponding twist-lock plug, thereby deflecting the flexible portions. When deflected, the flexible portions exert an opposing, biasing force in the direction of the male electrical contacts to maintain contact there between. One or more of a mounting base and a support base may be clamped to either or both sides of the printed circuit board to provide further stability for the flexible portions.

Description

BACKGROUNDTechnical Field

The present disclosure relates to electrical connectors, and more particularly to twist-lock connectors.

Description of the Related Art

Twist-lock connectors are used in many electrical applications where robust electrical connections and connector retention is desired. Historically, twist-lock connectors are made by crimping wire into stamped and formed electrical contacts made of brass, phosphor bronze, beryllium copper or other material. The electrical contacts are mounted in a base made of a non-conductive resin, such as Bakelite, or thermosetting plastic, or ceramic or other non-conductive material. The other end of the wires are then attached to a terminal block, connector, direct solder or other method of electrically connecting the wires to the module, lamp or Printed Circuit Board (PCB), which uses the electrical power or data conducted from the plugged-in connector (the connected device). The twist-lock connectors may include one or more female contacts that may electrically couple with corresponding male plug contacts.

Difficulties may arise when manufacturing traditional twist-lock connectors, which may therefore be prone to failure. For example, the stamped and formed contacts may not be perfectly formed so that the contact pressure of female contacts onto corresponding male plug contacts may vary greatly, leading to intermittent electrical connection, contact corrosion or loss of connection due to thermal expansion or contraction, or mechanical stress or vibration. In addition, crimping of the contacts to the wires may be incomplete or may damage the wire being crimped, thus causing failure of the connection. In some instances, the terminal block, connector or solder joint electrically connecting the wires to the module, lamp or Printed Circuit Board (PCB) may be improperly done, or may fail from thermal or mechanical stress or vibration. As a result, the wires may be strain relieved so that the wires will not break off or increase in electrical resistance when the wires are moved during servicing, or mechanical vibration.

Safety concerns may also be present in traditional twist-lock connectors. For example, the wires may become disconnected from either the crimped contact in the twist-lock connector, or the terminal block, receiving connector, solder joint, etc., and then move to make electrical connection with the conductive housing of the connected device, thereby presenting an electrical shock hazard.

In addition, the traditional twist-lock connector may also be relatively expensive to manufacture, with many steps of stamping and forming the contacts, crimping and terminating the wires, and may be difficult or expensive to install during final assembly of the connected device (for example, a luminaire) by requiring the assembler to install the wire ends into a terminal block through inserting a connector or soldering the wires into the connected device.

BRIEF SUMMARY

In some implementations, an electrical receptacle that accepts male twist-lock connectors may connect the corresponding contacts directly to an electronic printed circuit board without the need for stamped and formed contacts crimped to wires. In some implementations, the stamped and formed contacts may be eliminated in favor of either forming plated contacts on a PCB or soldering solid metal contacts to a PCB. In some implementations, crimping the wire and terminating the wire on stamped contacts may be eliminated by using traces on the PCB to connect to the circuitry on the PCB. Tolerances may be very tightly controlled (e.g., +/−0.003 inches) using PCB routing and plating production techniques. Such a PCB and electrical receptacle may be less expensive to produce compared to traditional twist-lock connectors by benefiting from the automatic assembly processes used in PCB fabrication and assembly.

A twist-lock connector that receives a set of male electrical contacts may be summarized as including: a set of female electrical receptacles that correspond to the set of male electrical contacts, the set of female electrical receptacles sized and dimensioned to receive the set of male electrical contacts, and the set of female electrical receptacles are physically engageable with the set of male electrical contacts when each of the male electrical contacts in the set of male electrical contacts are inserted into respective ones of the female electrical receptacles in the set of female electrical receptacles and rotated; a primary printed circuit board that has a first face and an opposing second face, the first face directed towards the female electrical receptacles; and a set of electrical connectors that correspond to the set of male electrical contacts, each of the electrical connectors positioned on respective ones of a set of flexible portions of the primary printed circuit board, each of the flexible portions resiliently deform responsive to one of the male electrical contacts contacting and exerting a force on the electrical connectors positioned on the flexible portion to provide a biasing force that urges the electrical connectors toward the male electrical contact.

The set of female electrical receptacles may include three female electrical receptacles arranged around a central point. The set of electrical connectors are comprised of brass plated with tin. Each of the flexible portions of the primary circuit board may be separated from remaining parts of the primary circuit board on a plurality of sides. Each flexible portion may comprise a proximal end and a distal end, the proximal end attached to the remaining part of the primary circuit board and the distal end separated therefrom. For each of the flexible portions, the electrical connector may be located proximate the distal end. The primary circuit board may include a composite mat that has a matrix, wherein the primary circuit board includes a pattern of elements, and wherein the pattern of elements is rotated by 60 degrees relative to the matrix of the composite mat. The twist-lock connector may further include: a secondary circuit board located on an opposite side of the female receptacles from the primary circuit board, the secondary circuit board includes a plurality of electrical connector pads arranged around a central axis. At least a subset of the plurality of electrical connector pads may provide dimming control for an electrically coupled luminaire. The twist-lock connector may further include: a support that is clamped next to the second face of the primary printed circuit board and biases the set of electrical connectors towards the female electrical receptacles. The twist-lock connector may further include: a screw that is threaded through and physically couples the support, the primary printed circuit board, and a mounting base that includes the set of female receptacles. The set of electrical connectors transitions to a biased position when the set of male electrical contacts may be rotatably engaged with the set of female electrical connections. The electrical connectors may include two opposing portions of the primary printed circuit board separated by a channel, wherein the channel is sized and positioned to engage with a respective one of the male electrical contacts when the male electrical contact is rotatably engaged with a corresponding one of the female electrical receptacles. Each of the respective flexible portions may include an internal tab that includes a fixed end and a free end.15. At least one of the electrical connectors may include an electrical post.

The twist-lock connector may further include a secondary circuit board located on an opposite side of the female receptacles from the primary circuit board, the secondary circuit board including a plurality of electrical connector pads arranged around a central axis. At least a subset of the plurality of electrical connector pads may provide dimming control for an electrically coupled luminaire.

The twist-lock connector may further include a support base that is clamped next to the second face of the primary printed circuit board and limits deflection of the flexible portions away from the female electrical receptacles.

The twist-lock connector may further include a mounting base that includes the set of female receptacles, the mounting base located opposite the support base across the primary printed circuit board.

The twist-lock connector may further include a screw that is threaded through and operable to clamp the support base, the primary printed circuit board, and the mounting base, wherein the mounting base is rotatable relative to the screw.

The twist-lock connector may further include a twist-lock plug, the twist-lock plug including the set of male electrical contacts, wherein the twist-lock plug further includes a photo-control component, and the mounting base may be rotatable to selectively position the photo-control component. The flexible portions may transition to a deformed position when the set of male electrical contacts are rotatably engaged with the set of female electrical receptacles. The electrical connectors may be comprised of two opposing portions of the primary printed circuit board separated by a channel, and the channel may be sized and positioned to engage with a respective one of the male electrical contacts when the male electrical contact is rotatably engaged with a corresponding one of the female electrical receptacles. Each of the respective flexible portions may be comprised of an internal tab that includes a fixed end and a free end. At least one of the electrical connectors may be comprised of an electrical post. The electrical post may include a proximal end and an opposing distal end, the proximal end may be located relatively closer to the primary circuit board and the distal end may be located relatively away from the primary circuit board, and the distal end may include a chamfer or tapered portion at an end that may be directed away from the primary circuit board.

A method of physically coupling a twist-lock connector with a twist-lock plug, the twist-lock plug including a plurality of male electrical contacts, the twist-lock connector including a plurality of female electrical receptacles and a primary printed circuit board that includes a set of flexible portions, such flexible portions including an electrical contact and aligning with respective ones of the female electrical receptacles, may be summarized as including inserting each of the male electrical contacts of the twist-lock plug into respective ones of the female electrical receptacles, the female electrical receptacles guide the male electrical contacts towards the electrical contacts on respective ones of the flexible portions; twisting the twist-lock plug with respect to the twist-lock connector, such twisting which securely engages the male electrical contacts with the respective ones of the female electrical receptacles; and deforming at least one of the flexible portions by the male electrical contacts into a deformed position responsive to one of the male electrical contacts contacting and exerting a force on the electrical contact positioned on the flexible portion. Deforming at least one of the flexible portions may include deforming at least one of the flexible portions in which the at least one flexible portion is separated from remaining parts of the primary circuit board on a plurality of sides. Deforming at least one of the flexible portions may include deforming the at least one of the flexible portions in the primary printed circuit board, the at least one of the flexible portions including a proximal end and a distal end, the proximal end attached to the remaining part of the primary circuit board and the distal end separated therefrom. The primary circuit board may be comprised of a composite mat that may have a matrix that includes a first axis and a second axis, and deforming at least one of the flexible portions may include deforming the at least one of the flexible portions of the primary printed circuit board, the primary circuit board including a pattern of elements, and the pattern of elements being rotated by a defined amount relative to the matrix of the composite mat.

The method may further include clamping a support base next to the primary printed circuit board, the support base which limits deflection of the flexible portions away the female electrical receptacles.

The method may further include clamping a mounting base to the primary printed circuit board, the mounting base which includes the plurality of female receptacles, the mounting base which is located opposite the support base across the primary printed circuit board.

The electrical contacts may be comprised of two opposing portions of the primary printed circuit board separated by a channel, and may further include engaging respective ones of the male electrical contacts within corresponding channels when the male electrical contact is rotatably engaged with a corresponding one of the female electrical receptacles.

The method may further include electrically coupling a set of electrical connectors to the primary printed circuit board, at least one electrical connector in the set of electrical connectors being electrically coupled to one of the flexible portions of the primary printed circuit board, wherein at least one of the electrical connectors in the set of electrical connectors may be comprised of brass plated with tin.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not necessarily intended to convey any information regarding the actual shape of the particular elements, and may have been solely selected for ease of recognition in the drawings.

FIG. 1 is an exploded elevated isometric view of a twist-lock connector that includes three printed circuit board (“PCB”) electrical connectors located on respective flexible portions, according to at least one illustrated implementation.

FIG. 2 is a side elevational view of a twist-lock connector, according to at least one illustrated implementation.

FIG. 3 is a top plan view of a primary PCB that is included within a twist-lock connector and that includes three flexible portions, each of which supports a PCB electrical connector, according to at least one illustrated implementation.

FIG. 4 is a bottom plan view of the primary PCB ofFIG. 3 positioned relative to a support base, according to at least one illustrated implementation.

FIG. 5 is an isometric view of a cavity of a mounting base that includes a plurality of spring guides, according to at least one illustrated implementation.

FIG. 6 is a top plan view of the mounting base ofFIG. 5 aligned with a PCB physically in which a portion of the mounting base is cut away to show the position of each of the plurality of spring guides with respect to the flexible portions of the PCB, according to at least one illustrated implementation.

FIG. 7 is a bottom isometric view of a bottom surface of a twist-lock connector with three male electrical contacts, according to at least one illustrated implementation.

FIG. 8 is a top plan view of a primary PCB that includes alternative flexible portions and respective PCB electrical connectors, according to at least one illustrated implementation.

DETAILED DESCRIPTION

In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations. However, one skilled in the relevant art will recognize that implementations may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with computer systems, server computers, and/or communications networks have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the implementations.

Unless the context requires otherwise, throughout the specification and claims that follow, the word “comprising” is synonymous with “including,” and is inclusive or open-ended (i.e., does not exclude additional, unrecited elements or method acts).

Reference throughout this specification to “one implementation” or “an implementation” means that a particular feature, structure or characteristic described in connection with the implementation is included in at least one implementation. Thus, the appearances of the phrases “in one implementation” or “in an implementation” in various places throughout this specification are not necessarily all referring to the same implementation. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more implementations.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the context clearly dictates otherwise.

The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the implementations.

FIG. 1 shows components of a twist-lock connector100 that includes three PCB mountedelectrical connectors102 located on respectiveflexible portions104 of aprimary PCB106, according to at least one illustrated implementation. The twist-lock connector100 may include theprimary PCB106, asupport base108, a mountingbase110, asecondary PCB112, and a mountingcoupler114.

Theprimary PCB106 may include afirst face116 and an opposingsecond face118 opposed across athickness119. Thefirst face116 and thesecond face118 may each be planar, and may be parallel to each other. Theprimary PCB106 may be comprised of one or more of a non-conductive resin or composite, such as fiberglass FR4, epoxy/Kevlar fiber or thermosetting plastic, or ceramic, or metal covered with nonconductive coating or film, or other non-conductive material. In some implementations, theprimary PCB106 may be circular in shape and may have a diameter of about 5 inches, although such shapes and dimensions should not be considered limiting. In some implementations, theprimary PCB106 may include a plurality of electrical traces or other electrically conductive pathways for conducting electrical signals. Theprimary PCB106 may include one or more apertures (“vias”) that extend between thefirst face116 and thesecond face118, with such apertures being used to electrically couple electronic components to one or more of the electrical traces or other conductive pathways. Such electrical coupling may be performed, for example, manually through soldering the electronic components, and/or such electrical coupling may be performed, for example, mechanically or automatically using pick-and-place technology. In some implementations, the electronic components and electrical traces and/or pathways may form an electronic circuit that performs one or more defined tasks. For example, in some implementations, such an electronic circuit may be used to control the operation of one or more luminaires, such as, for example, luminaires that provide lighting for roadways, streets, parking lots, and other large spaces.

Theprimary PCB106 may include one or moreflexible portions104 that may each support one or more PCB mountedelectrical connectors102. For example, as shown inFIG. 1, each of theflexible portions104 in theprimary PCB106 may support a respective PCBelectrical connector102. Theflexible portions104 may be formed within theprimary PCB106 using a standard PCB routing process to form cutouts adjacent to one or more sides of theflexible portion104 by removing a portion of theprimary PCB106. In some implementations, each of theflexible portions104 may be comprised of aninternal tab104athat includes afree end104bthat is physically separated from the remaining part of theprimary PCB106, and afixed end104cthat is fixed to or continuous with the remaining part of theprimary PCB106.

In some implementations, theflexible portion104 may be formed within an interior section of theprimary PCB106 by cutting out, routing, and/or otherwise removing portions of theprimary PCB106. In some implementations, a plurality of sides of theflexible portion104 may be physically separated from the remaining part of theprimary PCB106. In some implementations, for example, theflexible portion104 may form an “L” shape within theprimary PCB106 in which only the top part of the “L” is attached to theprimary PCB106. ThePCB106 proximate the remaining sides of the L-shapedflexible portion104 may be cut out, routed, or otherwise removed, thereby creating a separation or void between theflexible portion104 and the remaining part of theprimary PCB106 along these remaining sides. Such separation may enable theflexible portion104 to flex, deform, and move relative to the remaining part of theprimary PCB106.

The PCB mountedelectrical connectors102 may be comprised of conductive components soldered, riveted or otherwise attached to theflexible portions104 of theprimary PCB106. In some implementations, the PCB mountedelectrical connectors102 may be plated on theflexible portions104 using standard PCB manufacturing processes. In some implementations, plating may be formed around the edge of theflexible portions104 to make contact with male electrical contacts that may be inserted into the twist-lock connector100, and as such, may require that no contacts be soldered and/or crimped to electrical connections from theprimary PCB106. In some implementations, gold, tin, or other highly conductive metals may be plated on theflexible portions104 to achieve the relatively low resistance and contact corrosion resistance for the PCB mountedelectrical connectors102. In some implementations, the PCB mountedelectrical connectors102 may be cylindrical metal components supplied in tape and reel packaging, and automatically placed on theprimary PCB106 during standard automatic pick and place assembly, along with other components in the twist-lock connector100. In some implementations, the PCB mountedelectrical connectors102 may include an electrical post with a chamfer or tapered portion at an end that is directed towards the mountingbase110. Such a chamfer or tapered portion may facilitate engagement with other electrical connectors. Physical attachment and electrical connections may be made by reflow soldering with contacts that may be RoHS certified brass plated with tin, for example.

Theflexible portion104 may be resiliently deformable. As such, when a force is applied against theflexible portion104, as may occur, for example, when male electrical contacts come into contact with the PCB mountedelectrical connectors102, theflexible portion104 may exert a biasing force in an opposing direction. In some implementations, such an opposing force may be determined according to Hooke's Law of Spring Force that provides a linear relationship of force to distance of compression of the spring. As such, the biasing force applied by theflexible portion104 may urge the PCB mountedelectrical connectors102 towards the male electrical contacts. A process of routing theprimary PCB106 to form theflexible portions104 may provide advantages over conventional processing in which contacts are stamped by sequential stamping dies such that the contacts may have poor tolerances caused by die wear or other process variations. The tooling used for sequential stamping may be expensive, especially as compared to the tooling used for PCB fabrication. In addition, the contact force resulting from theflexible portions104 may be better controlled, with less variation between differentflexible portions104, because of the close dimensional tolerances used in PCB fabrication. In some implementations, one or both of thesupport base108 and/or the mountingbase110 may be used to provide additional support for theflexible portions104.

In some implementations, theprimary PCB106 may include one ormore registration apertures120 that may be used to align theprimary PCB106 with one or more other components in the twist-lock connector100. For example, theprimary PCB106 includes threemajor registration apertures120aand twominor registration apertures120bthat may be aligned with correspondingmajor registration projections122aandminor registration projections122bon thesupport base108 to thereby align theprimary PCB106 with thesupport base108.

Thesupport base108 may be comprised of non-conducting material. Such non-conducting material may include, for example, plastic resin, such as ABS resin. In some implementations, thesupport base108 may include a threadedportion124 that may be coupleable to the mountingcoupler114, such as a screw. In some implementations, thesupport base108 may include one or more spring guides126 in which eachspring guide126 may be aligned with at least a part of a respective one of theflexible portions104 on theprimary PCB106. When the components of the twist-lock connector100 are clamped together, each of the spring guides126 may be proximate to or in contact with the part of the respectiveflexible portion104 of theprimary PCB106. As such, when the male electrical contacts apply a force against the PCB mountedelectrical connectors102 going towards thesupport base108, placing theflexible portions104 in a deformed position, the spring guides126 in thesupport base108 may exert an opposing force, directed towards the mountingbase110, against the respectiveflexible portions104 of theprimary PCB106. Such a force, applied by the spring guides126 against theflexible portions104, may result in the position of theflexible portions104 being maintained with respect to the remaining part of the primary PCB106 (e.g., at least a portion of the outer surfaces of theflexible portions104 may be maintained within the planes formed by thefirst face116 and thesecond face118, respectively).). In some implementations, the spring guides126 may be used to limit an amount of deflection of theflexible portions104 when theflexible portions104 are in a deformed position.

The mountingbase110 may be comprised of non-conducting material. Such non-conducting material may include, for example, plastic resin, such as ABS resin. The mountingbase110 may be positioned between theprimary PCB106 and thesecondary PCB112. The mountingbase110 may include one or more femaleelectrical receptacles128 that may each be sized and dimensioned to securely receive a corresponding male electrical contact. Such male electrical contacts may be inserted into the respective ones of the femaleelectrical receptacles128 along a directedaxis130 that runs from the mountingbase110 to theprimary PCB106. The femaleelectrical receptacles128 may be used to guide each male electrical contact towards one of the PCB mountedelectrical connectors102.

The mountingbase110 may include a mountingbase surface132 that faces towards thesecondary PCB112 and aside wall134 that may extend from the first mountingbase surface132 towards theprimary PCB106. In some implementations, the mountingbase surface132 and theside wall134 may form acavity136 that has an opening that faces towards theprimary PCB106. Thecavity136 may include one or more spring guides (see, e.g.,FIG. 5 andFIG. 6) that may be used to maintain the position of theflexible portions104 of theprimary PCB106 with respect to the other portions of the primary PCB106 (e.g., at least a portion of the outer surfaces of theflexible portions104 may be maintained within the planes formed by thefirst face116 and thesecond face118, respectively). The first mountingbase surface132 may include a recessedportion144 that may be sized and dimensioned to receive thesecondary PCB112.

The mountingbase110 may include acentral aperture138 that may enable the mountingcoupler114 to pass through from the mountingbase surface132 towards thesupport base108. In some implementations, thecentral aperture138 may include anenlarged portion140 that may be used to next anupper portion142 of the mountingcoupler114 such that the mountingcoupler114 is flush with the mountingbase surface132 when the mountingcoupler114 is engaged with thesupport base108 to thereby clamp together the components of the twist-lock connector100. The femaleelectrical receptacles128 may be arranged around thecentral aperture138.

Thesecondary PCB112 may include afirst surface146 and an opposingsecond surface148 separated by athickness150. Thesecondary PCB112 may be annular in shape and may be sized to be received within the recessedportion144 of the mountingbase110. In some implementations, thesecondary PCB112 may be physically coupled to the mountingbase110 within the recessedportion144 using silicone or some other adhesive. The mountingcoupler114 may pass through the central open area of the annular region. In some implementations, thesecondary PCB112 may include one or moreelectrical contact pads152 that may electrically couple with electrical contacts on other devices mounted on the twist-lock connector100. Theelectrical contact pads152 may be arranged around acentral axis154 that extends through the central portion of thesecondary PCB112. In some implementations, two or fourelectrical contact pads152 may be used to provide a five or seven pin NEMA photo-control twist lock socket, respectively. Suchelectrical contact pads152 may be used to provide low voltage control of the controllable device. For example, many luminaires have 0 to 10 volt dimming control, where the low voltage signal sets the brightness of the luminaire. Digital Addressable Lighting Interface (DALI) control may use two low voltage control lines, which may be connected via two of theelectrical contact pads152. In some implementations, theelectrical contact pads152 may be plated with corrosion resistant plating such as gold or tin plating. In some implementations, theelectrical contact pads152 may be connected to theprimary PCB106 by a pluggable post and header connector. Such a pluggable post and header connector may thereby physically couple thesecondary PCB112 to the other components of the twist-lock connector100.

The mountingcoupler114 may extend through one or more components of the twist-lock connector100 to thereby clamp such components together. In some implementations, the mountingcoupler114 may be a screw with a countersunk head that may be securely received within theenlarged portion140 of thecentral aperture138 of the mountingbase110. The mountingcoupler114 may extend through thecentral aperture138 of the mountingbase110, theprimary PCB106 and be coupled with a corresponding coupling device in thesupport base108. Such a coupling device may include, for example, a threaded portion that may receive a corresponding threaded cavity of the mountingcoupler114. When so coupled, the mountingcoupler114 may thereby clamp together one or more components of the twist-lock connector100.

FIG. 2 shows the twist-lock connector100 in which the mountingbase110, theprimary PCB106, and thesupport base108 are clamped together by the mountingcoupler114, according to at least one illustrated implementation. In some implementations, thesecondary PCB112 may be physically and/or electrically coupled to theprimary PCB106 via a pluggable post and header connector (not shown). In some implementations, thesecondary PCB112 may be physically coupled to the mountingbase110 using silicone or some other adhesive. Themajor registration projections122aof thesupport base108 may extend through theregistration apertures120 from thefirst face116 to the opposingsecond face118 of theprimary PCB106. In some implementations, adistal portion200 of themajor registration projections122amay be located proximate theside wall134 of the mountingbase110. In some implementation, thedistal portions200 of themajor registration projections122amay come into contact with, and potentially engage, with a luminaire casting (not shown). In such an implementation, theprimary PCB106 andsupport base108 may be located within a cavity created by the luminaire casting, and thesecondary PCB112 and portions of the mountingbase110 may be located on an exterior portion of the luminaire casting. The mountingbase110 may include anannular seal202 that may extend around a circumference of a portion of the mountingbase110. In some implementations, theannular seal202 may engage with and be compressed by the luminaire casting to thereby form a seal to prevent water and/or particulates from entering an interior portion of the luminaire. Such a seal may further provide a frictional force between the twist-lock connector100 and luminaire casting to prevent rotation of the twist-lock connector100.

FIG. 3 shows theprimary PCB106 with threeflexible portions104, each of which may support a PCB electrical connector102 (not shown), according to at least one illustrated implementation. Theprimary PCB106 may be comprised of one or more of a non-conductive resin or composite, such as fiberglass FR4, or thermosetting plastic, or ceramic, or metal covered with nonconductive coating or film. In some implementations, theprimary PCB106 may be circular in shape and may have a diameter of about 5 inches or less, of between about 5 inches and 9 inches, or of about 9 inches or more, although such shapes and dimensions should not be considered limiting. In some implementations, theprimary PCB106 may include a plurality of electrical traces or other electrically conductive pathways for conducting electrical signals. Theprimary PCB106 may include one or more apertures that extend between thefirst face116 and thesecond face118, with such apertures being used to electrically couple electronic components to one or more of the electrical traces or other conductive pathways. Theprimary PCB106 may include a PCB laminate, such as a composite mat that has acomposite mat matrix304. In some implementations, the PCB pattern (e.g., the pattern of elements, such as electrical components, on the primary PCB106) may be rotated with respect to the axis formed by thecomposite mat matrix304. Such rotation, which may be by 60° for example, may provide eachflexible portion104 to have a similar alignment to thecomposite mat matrix304. Such similarity in alignment with respect to thecomposite mat matrix304 may reduce any variation between the forces applied by each respectiveflexible portion104 on theprimary PCB106 when theflexible portions104 are deformed. In some implementations, the force applied by each respectiveflexible portion104 on theprimary PCB106 when theflexible portions104 are deformed may be substantially equal.

Theflexible portions104 may be formed usingcutouts300 in which a part of theprimary PCB106 adjacent theflexible portions104 have been removed.Such cutouts300 may be formed within theprimary PCB106 using a standard PCB routing process to remove part of theprimary PCB106. For example, in some implementations,cutouts300 may be formed along a plurality of sides of theflexible portion104. Such aflexible portion104 may be resiliently deformed when a force is applied against theflexible portion104, as may occur, for example, when male electrical contacts come into contact with the PCB mountedelectrical connectors102. As a result, theflexible portion104 that has been deflected may exert a force in an opposing direction. When the original force is removed, theflexible portion104 may return to a non-deflected state wherein theflexible portion104 is coplanar with the remainder of theprimary PCT106.

In some implementations, the opposing force provided by aflexible portion104 that has been deflected may be determined according to Hooke's Law of Spring Force that provides a linear relationship of force to distance of deflection of the spring. As such, theflexible portion104 may generate a contact force based upon the displacement and/or deformation caused by the male electrical contacts applying a force in the opposite direction against the PCB mountedelectrical connectors102. A process of routing theprimary PCB106 to form thecutouts300 may provide advantages over conventional processing in which contacts are stamped by sequential stamping dies such that the contacts may have poor tolerances caused by die wear or other process variations. In addition, the contact force resulting from theflexible portions104 may be better controlled, with less variation between differentflexible portions104, because of the close dimensional tolerances used in PCB fabrication. In some implementations, one or both of thesupport base108 and/or the mountingbase110 may be used to provide additional support for theflexible portions104.

Theflexible portion104 may include multiple portions, as shown inFIG. 3. In such an implementation, for example, theflexible portion104 may include aprimary section306 that may have aproximal end308 and adistal end310. Theprimary section306 may be contiguous with the remaining portion of theprimary PCB106 at theproximal end308.Cutouts300 may be present along both sides of theprimary section306 that extend from theproximal end308 to thedistal end310. Theflexible portion104 may include asecondary section312 that has aproximal end314 and adistal end316. Theproximal end314 of thesecondary section312 of theflexible portion104 may be contiguous with thedistal end310 of theprimary section306 of theflexible portion104. The remaining portion of thesecondary section312 may be surrounded bycutouts300. Such aflexible portion104 may thereby form an “L” shape within theprimary PCB106 in which only the top part of the “L” (corresponding to theproximal end308 of the primary section306) is attached to the remaining portion of theprimary PCB106. In some implementations, the PCB mountedelectrical connectors102 may be positioned along or proximate the area in which theprimary section306 and thesecondary section312 of theflexible portion104 meet (e.g., proximate thedistal end310 of the primary section306).

FIG. 4 shows thesecond face118 of theprimary PCB106 positioned relative to thesupport base108, according to at least one illustrated implementation. In some implementations, thesupport base108 may be comprised of non-conducting material. Such non-conducting material may include, for example, plastic resin, such as ABS resin. In some implementations, thesupport base108 includes the threadedportion124 that may couple with the mountingcoupler114, such as a screw, to clamp together the components of the twist-lock connector100.

Thesupport base108 may include a plurality of spring guides126, each of which may be aligned with at least part of theflexible portions104 in theprimary PCB106. In some implementations, at least some of the spring guides126 may be aligned with at least a part of theflexible portions104 of theprimary PCB106. For example, as shown inFIG. 4, a plurality of first spring guides126amay each be aligned with asecondary section312 of respective ones of theflexible portions104 of theprimary PCB106. As such, the first spring guides126amay extend from theproximal end314 past thedistal end316 of thesecondary section312 of theflexible portion104. In some implementations, at least some of the spring guides126 may extend across at least a part of theflexible portions104 of theprimary PCB106. For example, a plurality of second spring guides126b(collectively, with first spring guides126a, “spring guides126”) may extend at an angle across part of theprimary section306 of theflexible portion104 of theprimary PCB106.

In some implementations, the spring guides126 may be used to maintain the position of theflexible portions104 of theprimary PCB106 with respect to the other portions of the primary PCB106 (e.g., at least a portion of the outer surfaces of theflexible portions104 may be maintained within the planes formed by thefirst face116 and thesecond face118, respectively). In some implementations, the spring guides126 may be used to limit an amount of deflection of theflexible portions104 when theflexible portions104 are in a deflected state. The spring guides126 may exert a force against thesecondary section312 of theflexible portions104 in the direction of the mountingbase110 when theflexible portions104 are in a deflected state. Such spring guides126 may prevent twisting or other deformations of theflexible portions104 when theflexible portions104 are in a deflected state, such as when corresponding male electrical contacts come into contact with the PCB mountedelectrical connectors102.

FIG. 5 shows thecavity136 of the mountingbase110 that includes a plurality of spring guides500, according to at least one illustrated implementation.FIG. 6 shows a cut-away view of the mountingbase110 that is aligned with theprimary PCB106 to show the position of each of the plurality of spring guides500 in the mountingbase110 with respect to theflexible portions104 of theprimary PCB106, according to at least one illustrated implementation. The mountingbase110 may be comprised of non-conducting material. Such non-conducting material may include, for example, plastic resin, such as ABS resin. The spring guides500 of the mountingbase110 may be comprised of two parts, aprimary part502 that aligns with theprimary section306 of theflexible portion104 of theprimary PCB106, and asecondary part504 that aligns with thesecondary section312 of theflexible portion104 of theprimary PCB106. As such, when the mountingbase110 is aligned with theprimary PCB106, theprimary part502 of thespring guide500 may extend from theproximal end308 towards thedistal end310 of theprimary section306 of theflexible portion104 of theprimary PCB106. When the mountingbase110 is aligned with theprimary PCB106, thesecondary part504 of thespring guide500 may extend from theproximal end314 towards thedistal end316 of thesecondary section312 of theflexible portion104 of theprimary PCB106. As such, theprimary part502 and/or thesecondary part504 of the spring guides500 in the mountingbase110 may be used in some implementations to maintain the position of theflexible portions104 of theprimary PCB106 with respect to the other portions of the primary PCB106 (e.g., at least a portion the outer surfaces of theflexible portions104 may be maintained within the planes formed by thefirst face116 and thesecond face118, respectively). In some implementations, theprimary part502 and/or thesecondary part504 of the spring guides500 in the mountingbase110 may be used to limit an amount of deflection of theflexible portions104 when theflexible portions104 are in a deflected state.

In some implementations, acurved section506 of each of the spring guides500 may extend between theprimary part502 and thesecondary part504 of the spring guide in the mountingbase110. Such acurved section506 may have a radius of curvature that provides sufficient space for the PCB mounted electrical connectors102 (FIG. 1) to extend out from theprimary PCB106 towards the mountingbase110. In some implementations, thecurved section506 may include an interiorconcave wall508 that may be located proximate the PCB mountedelectrical connectors102 when theprimary PCB106 and mountingbase110 are aligned. As such, the interiorconcave wall508 may be used to maintain the position of the respective PCB mountedelectrical connectors102 when the male electrical contacts are inserted into the femaleelectrical receptacles128 and twisted to thereby securely engage and electrically couple the male electrical contacts with the PCB mountedelectrical connectors102. For example, in some implementations, the male electrical contacts may be part of a turn-lock plug in which the male electrical contacts have a distal end that includes an offset portion that can be inserted fully into the corresponding femaleelectrical receptacles128. When turned, the offset portion of the male electrical contacts may engage with a corresponding edge orlip512 for each respective femaleelectrical receptacle128 that may holds the distal end of the male electrical contact within the respective femaleelectrical receptacle128. When locked within the femaleelectrical receptacles128, the male electrical contacts may be maintained in contact, and thereby be electrically coupled, with the PCB mountedelectrical connectors102. When securely engaged, the male electrical contacts may place theflexible portions104 of theprimary PCB106 in a deflected position.

In some implementations, the mountingbase110 may include one ormore registration cavities510 that may engage with one or more correspondingminor registration projections122b(FIG. 1) from thesupport base108. In some implementations, theregistration cavities510 may be placed in a non-symmetrical formation within thecavity136 of the mountingbase110 such that theregistration cavities510 properly align with the corresponding registration projections112bof thesupport base108 in only one configuration.

FIG. 7 shows abottom surface704 of a twist-lock plug700 with three maleelectrical contacts702, according to at least one illustrated implementation. The maleelectrical contacts702 may include aproximal part706 and adistal part708 in which theproximal part706 is located relatively closer to thebottom surface704, and thedistal part708 is located relatively away from thebottom surface704. Theproximal part706 may extend perpendicularly out from thebottom surface704 of the twist-lock plug700. In some implementations, thedistal part708 may include an offsetportion710 that is offset from theproximal part706 of the maleelectrical contact702. The offsetportion710 may include anedge712 that extends parallel to thebottom surface704 of the twist-lock plug700. When the maleelectrical contacts702 are inserted into the femaleelectrical receptacles128 and twisted, theedge712 of the offsetportion710 of the maleelectrical contacts702 may engage with the corresponding edge or lip512 (FIG. 5) of the femaleelectrical receptacle128 to thereby securely engage and physically couple the twist-lock plug700 with the mountingbase110 of the twist-lock connector100.

In some implementations, the twist-lock plug700 may include one or moreelectrical connectors714 that may be used to electrically couple with theelectrical contact pads152 on thesecondary PCB112. Suchelectrical connectors714 and correspondingelectrical contact pads152 may be used for a five or seven pin NEMA photo-control twist-lock socket, respectively, that may provide low voltage control of the controllable device. For example, many luminaires have 0 to 10 volt dimming control, where the low voltage signal sets the brightness of the luminaire. Digital Addressable Lighting Interface (DALI) control may include two low voltage control lines, which may be connected via two sets of theelectrical connectors714 and correspondingelectrical contact pads152.

In some implementations, the twist-lock plug700 may provide photo-control for a luminaire when engaged and electrically coupled with a corresponding twist-lock connector100 in the luminaire. In such an implementation, the mountingcoupler114 in the twist-lock connector100 may be loosened, allowing for the rotation of the remaining components of the twist-lock connector100 such that the photo-control components in the twist-lock plug700 may be aligned to a more optically favorable position.Projections122bengage inrecesses510 to keep the mountingbase110, theprimary PCB106 and/or thesupport base108 aligned during rotation. The mountingcoupler114 may then be tightened to clamp together the components of the twist-lock connector100, thereby maintaining the position of the twist-lock connector100. The twist-lock plug700 with the photo-control may then be engaged with and installed in the twist-lock connector100. Such a rotatable feature may be advantageous in installations where there may be other light sources or light reflectors (such as tree branches) which may cause undesirable operation of the photo-control if not oriented in a particular direction.

FIG. 8 shows aPCB800 that includes alternativeflexible portions802 and respective PCBelectrical connectors804, according to at least one illustrated implementation. The PCBelectrical connectors804 may be formed directly onto thePCB800, including the edge of theflexible portions802. Such PCBelectrical connectors804 may include two opposing

portions

810a,810bseparated by achannel812. Thechannel812 may be sized and positioned to engage with a respective one of the maleelectrical contacts702 from the twist-lock plug700 when the maleelectrical contact702 is inserted into and rotatably engaged with a corresponding one of the femaleelectrical receptacles128 in the mountingbase110. When engaged, each maleelectrical contact702 may be positioned within a corresponding one of thechannels812 of the PCBelectrical connectors804 in which the maleelectrical contact702 physically engages and deflects (e.g., pushes apart) the two opposing

portions

810a,810b. Routedareas808 in thePCB800 proximate the PCBelectrical connectors804 may provide clearance for the male electrical contacts from the twist-lock plug700 to be inserted and then twisted to be physically and electrically coupled to the PCBelectrical connectors804. In such an implementation, the PCBelectrical connectors804 may be electrically coupled to other electrical components on thePCB800 via PCB traces806 in thePCB800.

The foregoing detailed description has set forth various implementations of the devices and/or processes via the use of block diagrams, schematics, and examples. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one implementation, the present subject matter may be implemented via Application Specific Integrated Circuits (ASICs). However, those skilled in the art will recognize that the implementations disclosed herein, in whole or in part, can be equivalently implemented in standard integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more controllers (e.g., microcontrollers) as one or more programs running on one or more processors (e.g., microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and or firmware would be well within the skill of one of ordinary skill in the art in light of this disclosure.

Those of skill in the art will recognize that many of the methods or algorithms set out herein may employ additional acts, may omit some acts, and/or may execute acts in a different order than specified.

In addition, those skilled in the art will appreciate that the mechanisms taught herein are capable of being distributed as a program product in a variety of forms, and that an illustrative implementation applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of signal bearing media include, but are not limited to, the following: recordable type media such as floppy disks, hard disk drives, CD ROMs, digital tape, and computer memory.

These and other changes can be made to the implementations in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific implementations disclosed in the specification and the claims, but should be construed to include all possible implementations along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims

The invention claimed is:

1. A twist-lock connector that receives a set of male electrical contacts, the twist-lock connector comprising:

a set of female electrical receptacles that correspond to the set of male electrical contacts, the set of female electrical receptacles sized and dimensioned to receive the set of male electrical contacts, and the set of female electrical receptacles are physically engageable with the set of male electrical contacts when each of the male electrical contacts in the set of male electrical contacts are inserted into respective ones of the female electrical receptacles in the set of female electrical receptacles and rotated;

a primary printed circuit board that has a first face and an opposing second face, the first face directed towards the female electrical receptacles; and

a set of electrical connectors that correspond to the set of male electrical contacts, each of the electrical connectors positioned on respective ones of a set of flexible portions of the primary printed circuit board, each of the flexible portions resiliently deform responsive to one of the male electrical contacts contacting and exerting a force on the electrical connector positioned on the flexible portion to provide a biasing force that urges the electrical connector toward the male electrical contact.

2. The twist-lock connector ofclaim 1 wherein the set of female electrical receptacles includes three female electrical receptacles arranged around a central point.

3. The twist-lock connector ofclaim 1 wherein the set of electrical connectors are comprised of brass plated with tin.

4. The twist-lock connector ofclaim 1 wherein each of the flexible portions of the primary circuit board is separated from remaining parts of the primary circuit board on a plurality of sides.

5. The twist-lock connector ofclaim 1 wherein each flexible portion comprises a proximal end and a distal end, the proximal end attached to the remaining part of the primary circuit board and the distal end separated therefrom.

6. The twist-lock connector ofclaim 5 wherein, for each of the flexible portions, the electrical connector is located proximate the distal end.

7. The twist-lock connector ofclaim 1 wherein the primary circuit board is comprised of a composite mat that has a matrix, wherein the primary circuit board includes a pattern of elements, and wherein the pattern of elements is rotated by a defined amount relative to the matrix of the composite mat.

8. The twist-lock connector ofclaim 7 wherein the matrix includes a first axis and a second axis, wherein each flexible portion extends in a direction from a proximal end to a distal end, and wherein the pattern of elements on the primary printed circuit board is rotated relative to the matrix of the composite mat such that the respective direction in which each flexible portion extends is parallel to at least one of the first axis and the second axis of the matrix.

9. The twist-lock connector ofclaim 1, further comprising:

a secondary circuit board located on an opposite side of the female receptacles from the primary circuit board, the secondary circuit board includes a plurality of electrical connector pads arranged around a central axis.

10. The twist-lock connector ofclaim 9 wherein at least a subset of the plurality of electrical connector pads provides dimming control for an electrically coupled luminaire.

11. The twist-lock connector ofclaim 9, further comprising:

a support base that is clamped next to the second face of the primary printed circuit board and limits deflection of the flexible portions away from the female electrical receptacles.

12. The twist-lock connector ofclaim 11, further comprising:

a mounting base that includes the set of female receptacles, the mounting base located opposite the support base across the primary printed circuit board.

13. The twist-lock connector ofclaim 12, further comprising:

a screw that is threaded through and operable to clamp the support base, the primary printed circuit board, and the mounting base, wherein the mounting base is rotatable relative to the screw.

14. The twist-lock connector ofclaim 13, further comprising:

a twist-lock plug, the twist-lock plug includes the set of male electrical contacts, wherein the twist-lock plug further includes a photo-control component, and the mounting base is rotatable to selectively position the photo-control component.

15. The twist-lock connector ofclaim 11 wherein the flexible portions transition to a deformed position when the set of male electrical contacts are rotatably engaged with the set of female electrical receptacles.

16. The twist-lock connector ofclaim 1 wherein the electrical connectors are comprised of one or more opposing portions of the primary printed circuit board separated by a channel, wherein the channel is sized and positioned to engage with a respective one of the male electrical contacts when the male electrical contact is rotatably engaged with a corresponding one of the female electrical receptacles.

17. The twist-lock connector ofclaim 1 wherein each of the respective flexible portions is comprised of an internal tab that includes a fixed end and a free end.

18. The twist-lock connector ofclaim 1 wherein at least one of the electrical connectors is comprised of an electrical post.

19. The twist-lock connector ofclaim 18, wherein the electrical post include a proximal end and an opposing distal end, wherein the proximal end is located relatively closer to the primary circuit board and the distal end is located relatively away from the primary circuit board, and wherein the distal end includes a chamfer or tapered portion at an end that is directed away from the primary circuit board.

20. A method of physically coupling a twist-lock connector with a twist-lock plug, the twist-lock plug including a plurality of male electrical contacts, the twist-lock connector including a plurality of female electrical receptacles and a primary printed circuit board that includes a set of flexible portions, such flexible portions including an electrical contact and aligning with respective ones of the female electrical receptacles, the method comprising:

inserting each of the male electrical contacts of the twist-lock plug into respective ones of the female electrical receptacles, the female electrical receptacles guide the male electrical contacts towards the electrical contacts on respective ones of the flexible portions;

twisting the twist-lock plug with respect to the twist-lock connector, such twisting which securely engages the male electrical contacts with the respective ones of the female electrical receptacles; and

deforming at least one of the flexible portions by the male electrical contacts into a deformed position responsive to one of the male electrical contacts contacting and exerting a force on the electrical contact positioned on the flexible portion.

21. The method ofclaim 20 wherein deforming at least one of the flexible portions comprises deforming at least one of the flexible portions in which the at least one flexible portion is separated from remaining parts of the primary circuit board on a plurality of sides.

22. The method ofclaim 20 wherein deforming at least one of the flexible portions comprises deforming the at least one of the flexible portions in the primary printed circuit board, wherein the at least one of the flexible portions comprises a proximal end and a distal end, the proximal end attached to the remaining part of the primary circuit board and the distal end separated therefrom.

23. The method ofclaim 22 wherein the primary circuit board is comprised of a composite mat that has a matrix that includes a first axis and a second axis, and wherein deforming at least one of the flexible portions comprises deforming the at least one of the flexible portions of the primary printed circuit board, wherein the primary circuit board includes a pattern of elements, and wherein the pattern of elements is rotated by a defined amount relative to the matrix of the composite mat.

24. The method ofclaim 20, further comprising:

clamping a support base next to the primary printed circuit board, the support base which limits deflection of the flexible portions away the female electrical receptacles.

25. The method ofclaim 24, further comprising:

clamping a mounting base to the primary printed circuit board, the mounting base which includes the plurality of female receptacles, the mounting base which is located opposite the support base across the primary printed circuit board.

26. The method ofclaim 20 wherein the electrical contacts are comprised of one or more portions of the primary printed circuit board separated by a channel, further comprising:

engaging respective ones of the male electrical contacts within corresponding channels when the male electrical contact is rotatably engaged with a corresponding one of the female electrical receptacles.

27. A method of manufacturing a twist lock connector that includes a mounting base, a support base, and a primary printed circuit board, the mounting base which includes at least one female electrical receptacle, the method comprising:

routing one or more portions of the primary printed circuit board to form one or more cut out sections, each cut out section surrounding a respective flexible portion of the primary printed circuit board in which each respective flexible portion resiliently deforms responsive to a force being applied to the flexible portion;

mounting the primary printed circuit board between the mounting base and the support base; and

clamping the mounting base, the primary printed circuit board, and the support base such that each of the at least one female electrical receptacles is aligned with respective ones of the flexible portions of the primary printed circuit board.

28. The method ofclaim 27 wherein routing one or more portions of the primary printed circuit board to form one or more cut out sections includes routing at least three portions of the primary printed circuit board to form at least three flexible portions of the primary printed circuit board.

29. The method ofclaim 27, further comprising:

electrically coupling a set of electrical connectors to the primary printed circuit board, at least one electrical connector in the set of electrical connectors being electrically coupled to one of the flexible portions of the primary printed circuit board, wherein at least one of the electrical connectors in the set of electrical connectors is comprised of brass plated with tin.

30. The method ofclaim 27, wherein the primary printed circuit board is comprised of a composite mat that has a matrix that includes a first axis and a second axis and wherein the primary printed circuit board includes a pattern of elements, the method further comprising:

rotating the pattern of elements in the primary printed circuit board a defined amount relative to the matrix of the composite mat.

31. The method ofclaim 30 wherein the matrix includes a first axis and a second axis, wherein each flexible portion extends in a direction from a proximal end to a distal end, and wherein rotating the pattern of elements on the primary printed circuit board includes rotating the pattern of elements on the primary printed circuit board such that the respective direction in which each flexible portion extends is parallel to at least one of the first axis and the second axis of the matrix.

32. The method ofclaim 27 wherein clamping the mounting base, the primary printed circuit board, and the support base further includes clamping the support base and the primary printed circuit board to thereby limit an amount of deflection of the flexible portions of the primary printed circuit board away from the female electrical receptacles in response to the force being applied to the flexible portions.